Low-profile Drain

ABSTRACT

A low-profile drain includes a drain body configured to direct liquids into a drainage system, the drain body having an upper barrel and a lower barrel. A flange extends outwardly from the upper barrel of the drain body. A bondable waterproof membrane is attached to an upper surface of the flange and extending outwardly away from the flange. A bonding fleece is attached to a lower surface of the flange.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates generally to floor drain installations.

Related Art

Numerous drains have been developed for installation with ceramic tile, stone and similar veneer flooring materials. While such drains generally function well for the purpose for which they were designed, they can often impose height limitations on the surrounding installation. For example, the surrounding flooring installation may have to be installed to an undesirable height in order to sufficiently affix the drain in position, or the surrounding subfloor may need to be modified to accommodate these conventional drains.

SUMMARY OF THE INVENTION

In accordance with one aspect of the invention, a low-profile drain is provided, including a drain body configured to direct liquids into a drainage system. The drain body can have an upper barrel and a lower barrel. A flange can extend outwardly from the upper barrel of the drain body. A bondable waterproof membrane can be attached to an upper surface of the flange and can extend outwardly away from the flange. A bonding fleece can be attached to a lower surface of the flange.

In accordance with another aspect of the invention, a low-profile drain is provided, including a drain body configured to direct liquids into a drainage system, the drain body having an upper barrel and a lower barrel. A flange can extend outwardly from the upper barrel of the drain body. A bondable waterproof membrane can be attached to an upper surface of the flange and can extend outward away from the flange. A bonding fleece can be attached to a lower surface of the flange. The flange can extend outwardly from the drain body in a substantially flat plane so as to be configured to lie flat against a surrounding subfloor surface.

In accordance another aspect of the invention, a low-profile drain is provided, including a drain body configured to direct liquids into a drainage system. The drain body can have an upper barrel and a lower barrel. A flange can extend outwardly from the upper barrel of the drain body. A bondable waterproof membrane can be attached to an upper surface of the flange and can extend outward away from the flange. A bonding fleece can be attached to a lower surface of the flange. Each of the flange, the bondable waterproof membrane and the bonding fleece can have a thickness. The flange can terminate in four planar edges and can extend outwardly from the drain body in a substantially flat plane so as to be configured to lie flat against a surrounding subfloor surface.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate exemplary embodiments for carrying out the invention. Like reference numerals refer to like parts in different views or embodiments of the present invention in the drawings.

FIG. 1 is a bottom perspective view of a low-profile drain in accordance with an aspect of the present technology;

FIG. 2 is a top perspective of the drain of FIG. 1, shown with portions of a bondable waterproof membrane folded inwardly over a body of the drain;

FIG. 3 is a bottom view of the drain of FIG. 1;

FIG. 4 is a top view of the drain of FIG. 1;

FIG. 5 is a side view of a portion of the drain of FIG. 1;

FIG. 6 is a side view of the drain of FIG. 1 in a flooring installation.

DETAILED DESCRIPTION

Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.

Definitions

As used herein, the singular forms “a” and “the” can include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a bondable waterproof membrane” can include one or more of such membranes, if the context so dictates.

As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. As an arbitrary example, an object that is “substantially” enclosed is an article that is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend upon the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. As another arbitrary example, a composition that is “substantially free of” an ingredient or element may still actually contain such item so long as there is no measurable effect as a result thereof.

As used herein, the term “bondable (or bonded) waterproof membrane” refers to a membrane that typically bonds directly to a mortar bed or shower tray (or a suitable equivalent) that protects the mortar bed or shower tray (and any underlying structure such as the subfloor) from contact with moisture from the shower. Such membranes are well known, such as the version commercially sold under the trademark “Kerdi®.”

As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint.

Relative directional terms can sometimes be used herein to describe and claim various components of the present invention. Such terms include, without limitation, “upward,” “downward,” “horizontal,” “vertical,” etc. These terms are generally not intended to be limiting, but are used to most clearly describe and claim the various features of the invention. Where such terms must carry some limitation, they are intended to be limited to usage commonly known and understood by those of ordinary skill in the art in the context of this disclosure.

While a good faith effort has been made to accurately depict relative dimensions of various components in the figures, the figures may present components in a manner that is slightly enlarged or reduced in size to more accurately convey the principals of the present technology.

As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. Thus, no individual member of such list should be construed as a de facto equivalent of any other member of the same list solely based on their presentation in a common group without indications to the contrary.

Numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5, individually.

This same principle applies to ranges reciting only one numerical value as a minimum or a maximum. Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described.

INVENTION

The present technology relates generally to low-profile drains for use in veneer flooring installations such as ceramic tile, stone and the like. The drains of the present technology present a much lower profile than conventional drains, on the order of an inch or more less height than some prior art drains. The present drains can be set essentially flush with surrounding tile installations such that a height of the surrounding floor need not be altered to accommodate the drain.

As shown generally in the figures, the present technology provides a drain 10 that can be used to provide a low-profile drainage point in a variety of flooring installations. The drain can include a drain body 12 configured to direct liquids into a drainage system (not shown). The drain body can include an upper barrel 14 and a lower barrel 16. A flange 18 can extend outwardly from the upper barrel of the drain body. A bondable waterproof membrane 20 can be attached to an upper surface of the flange and can extend outwardly away from the flange. A bonding fleece 22 can be attached to a lower surface of the flange. In the example shown, the flange can extend outwardly from the drain body in a substantially flat plane so as to be configured to lie flat against a surrounding subfloor surface.

FIG. 6 illustrates a nearly complete floor installation incorporating the present drain 10. As is customary, a subfloor structure 30, which can be a wooden structure, concrete structure, etc., generally includes an opening 32 formed therethrough. The drain body 12 is inserted through this opening as it is attached to the overall drainage system (not shown) below. As liquids pass over the floor, they are directed into the upper barrel 14 of the drain body, eventually passing through the lower barrel 16 into the drainage system below. Oftentimes, a membrane 34, such as that commercially available as Schluter Kerdi® membrane, is applied over the entirety of the subfloor prior to installation of any of the veneer materials atop the subfloor.

As the drain is installed through the opening 32, the bonding fleece 22 can be bonded to the membrane 34 (or to the subfloor itself in the case a membrane is not utilized). The bondable waterproof membrane 20 is then spread flat outwardly from the drain and also bonded to the membrane 34 or to the subfloor. Mortar or other adhesive 36 can be applied over the bondable waterproof membrane so that tiles or other veneer materials 38 can be bonded in place with the mortar. A grout or similar material can be applied in spaces 40 between the veneer materials.

As will be appreciated by one of ordinary skill in the art having possession of this disclosure, the low-profile design of the present drain allows installation of the drain substantially flush with the surrounding tile. Thus, the drains of the present technology are well suited for use in flat areas where it is not desired to either elevate the overall flooring installation, or to lower the subfloor structure, which are otherwise necessary for many conventional drain designs. The drains are particularly well suited for secondary drains, which are often installed outside a shower area, in a generally flat floor, to capture excess water from the adjacent shower area.

The present design provides an overall height that is an inch or more less than conventional designs. A diameter “D” of the barrel of the drain body 12 can be limited in size such that the opening 32 formed in the subfloor is as small as about 4.5 inches. Thus, the drain can be installed in areas of limited space without significantly affecting the surrounding floor area.

As shown in FIG. 2, the bondable waterproof membrane is typically a very flexible material that extends outwardly from the flange 18. An installer will generally fold the membrane in on itself, in the configuration shown in FIG. 2, during installation of the drain within and on the subfloor. Once properly positioned, the bondable waterproof membrane is typically laid flat in the configuration shown in FIG. 3 (note that this is a bottom view, showing the bonding fleece 22 which will be attached immediately above the subfloor or subfloor membrane—FIG. 4 shows the same layout from a top view). As will be appreciated from this view, the flange 22 extends outwardly from the upper barrel of the drain body in a first axis, marked as the “x” axis, and a second axis, marked as the “y” axis. The second axis is generally orthogonal to the first axis. In one exemplary embodiment, a distance that the flange extends in the first axis is substantially equal to a distance the flange extends in the second axis. Thus, the flange can extend symmetrically outwardly from the drain body.

As will also be appreciated from FIG. 3, in one exemplary embodiment, the bondable waterproof membrane 20 extends outwardly from the flange in the first axis and the second axis. Similar to the flange, a distance the bondable waterproof membrane extends in the first axis is substantially equal to a distance the bondable waterproof membrane extends in the second axis. Thus, the bondable waterproof membrane can extend symmetrically outwardly from the drain body. As will also be appreciated from this view, the flange can terminate in at least one flange edge that is generally planar. In the examples shown, all four flange edges are planar. This can aid in installing the drain adjacent other structures, such as walls, surrounds, etc.

As also shown most clearly in FIG. 3, in one embodiment of the invention, the bonding fleece 22 can substantially completely cover the lower surface of the flange. This can ensure that lower portion of the flange, and thus the drain, is securely bonded to the underlying subfloor or subfloor membrane.

In one aspect of the invention, the bottom of the flange 18 is substantially flat, and can thus lie flatly against the adjacent subfloor, with a thin layer of mortar or other adhesive applied in a layer having a uniform thickness. That is, the mortar or other adhesive between the bonding fleece and the subfloor (or a membrane applied over a subfloor) need not be built up or sloped—it is a constant thickness as the flange extends from near the drain body toward outer edges of the flange. This results in a top of the flange being a uniform distance from the top of the subfloor, across the installation. Contrast this aspect of the technology with existing drains, which often require that an installer apply a significant amount of mortar over the subfloor to ensure that a drain can be fully set within the mortar and be thereby bonded in place. Many times, this mortar bed was required to be sloped, as the drain sloped from outer edges of the conventional drains toward the throat of the drains.

The bonding fleece 22 and the bondable waterproof membrane 20 can be formed from similar, but differing materials. In one non-limiting example, the bonding fleece is formed from polypropylene. In one non-limiting example, the bondable waterproof membrane is formed from a modified polyethylene (PEVA) core with non-woven polypropylene on both sides. The bondable waterproof membrane can be around 8 mils thick, with a water vapor permeance of about 0.90 perms.

Turning now to FIG. 5, in one aspect of the invention, each of the flange 18, the bondable waterproof membrane 20 and the bonding fleece 22 have a thickness. The thickness of the flange is shown at T₁₈, the thickness of the bondable waterproof membrane is shown at T₂₀ and the thickness of the bonding fleece is shown at T₂₂. In this embodiment, a combined thickness T_(O) of the flange, the bondable waterproof membrane and the bonding fleece is less than about 0.50 inches. In another embodiment, the combined thickness is less than about 0.25 inches. This can ensure that a low profile is maintained between the drain components and the adjacent flooring materials.

As also shown in FIG. 6, the flange 18 can extend from the drain body 12 at an angle relative to a center vertical axis of the drain body; in this example, the vertical axis is shown as axis “z” and the axis at which the flange extends is shown as axis “x.” The angle α between the two axis can be between about 90 degrees and about 95 degrees. In one embodiment, the angle is about 90 degrees, representing zero slope from the outer edges of the flange to the point where the flange extends from the drain body.

The various components of the drain can be formed from a variety of materials. In one embodiment, the drain body and flange are formed as a unitary piece of a polymeric material, such as ABS (Acrylonitrile Butadiene Styrene) or PVC (Polyvinyl Chloride).

It is to be understood that the above-referenced arrangements are illustrative of the application for the principles of the present invention. Numerous modifications and alternative arrangements can be devised without departing from the spirit and scope of the present invention while the present invention has been shown in the drawings and described above in connection with the exemplary embodiments(s) of the invention. It will be apparent to those of ordinary skill in the art that numerous modifications can be made without departing from the principles and concepts of the invention as set forth in the examples. 

1. A low-profile drain, comprising: a drain body configured to direct liquids into a drainage system, the drain body having an upper barrel and a lower barrel; a flange extending outwardly from the upper barrel of the drain body, the flange extending outwardly from the drain body in a substantially flat plane so as to be configured to lie flat against a surrounding flat subfloor surface; and a bondable waterproof membrane attached to an upper surface of the flange and extending outwardly away from the flange.
 2. The drain of claim 1, further comprising a bonding fleece attached to a lower surface of the flange.
 3. The drain of claim 1, wherein each of the flange, the bondable waterproof membrane and the bonding fleece having a thickness, and wherein a combined thickness of the flange, the bondable waterproof membrane and the bonding fleece is less than about 0.25 inches above the surrounding flat subfloor.
 4. The drain of claim 1, wherein the flange extends outwardly from the upper barrel of the drain body in a first axis and a second axis, the second axis orthogonal to the first axis, and wherein a distance the flange extends in the first axis is substantially equal to a distance the flange extends in the second axis.
 5. The drain of claim 4, wherein the bondable waterproof membrane extends outwardly from the flange in the first axis and the second axis, and wherein a distance the bondable waterproof membrane extends in the first axis is substantially equal to a distance the bondable waterproof membrane extends in the second axis.
 6. The drain of claim 1, wherein the flange terminates in at least one flange edge, the at least one flange edge being planar.
 7. The drain of claim 1, wherein the flange extends from the drain body at an angle relative to a center vertical axis of the drain body, the angle being between about 90 degrees and about 95 degrees.
 8. The drain of claim 7, wherein angle is about 90 degrees.
 9. The drain of claim 1, wherein the drain body and flange are formed of a unitary piece of a polymeric material.
 10. The drain of claim 1, wherein bonding fleece substantially completely covers the lower surface of the flange.
 11. A low-profile drain, comprising: a drain body configured to direct liquids into a drainage system, the drain body having an upper barrel and a lower barrel; a flange extending outwardly from the upper barrel of the drain body; a bondable waterproof membrane attached to an upper surface of the flange and extending outward away from the flange, the bondable waterproof membrane being foldable inwardly over the drain body; and a bonding fleece attached to a lower surface of the flange; the flange extending outwardly from the drain body in a substantially flat plane so as to be configured to lie flat against a surrounding flat subfloor surface.
 12. The drain of claim 11, wherein the flange extends outwardly from the upper barrel of the drain body in a first axis and a second axis, the second axis orthogonal to the first axis, and wherein a distance the flange extends in the first axis is substantially equal to a distance the flange extends in the second axis.
 13. The drain of claim 11, wherein the bondable waterproof membrane extends outwardly from the flange in the first axis and the second axis, and wherein a distance the bondable waterproof membrane extends in the first axis is substantially equal to a distance the bondable waterproof membrane extends in the second axis.
 14. The drain of claim 11, wherein the flange terminates in at least one flange edge, the at least one flange edge being planar.
 15. The drain of claim 11, wherein the flange extends from the drain body at an angle relative to a center vertical axis of the drain body, the angle being between about 90 degrees and about 95 degrees.
 16. The drain of claim 15, wherein angle is about 90 degrees.
 17. The drain of claim 11, wherein the drain body and flange are formed of a polymeric material.
 18. A low-profile drain, comprising: a drain body configured to direct liquids into a drainage system, the drain body having an upper barrel and a lower barrel; a flange extending outwardly from the upper barrel of the drain body; a bondable waterproof membrane attached to an upper surface of the flange and extending outward away from the flange; and a bonding fleece attached to a lower surface of the flange; the flange terminating in four planar edges and extending outwardly from the drain body in a substantially flat plane so as to be configured to lie flat against a surrounding subfloor surface.
 19. The drain of claim 18, wherein the bondable waterproof membrane terminates in four planar edges.
 20. The drain of claim 18, wherein bonding fleece substantially completely covers the lower surface of the flange. 